Fuel Cell Connector Modules for Positional Deviation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors for fuel cell stacks face challenges in maintaining connection reliability and downsizing due to positional deviations of cells caused by dimensional errors and vibrations, which lead to excessive displacement and wear of contact points, limiting the absorption of relative displacement and applying excess load on contacts and electrodes.
Innovation Solution
A connector unit comprising stacked modules with a holding portion and coupling portions, including protrusions and concave parts, allows for individual displacement in multiple directions to absorb positional deviations, preventing separation and maintaining contact reliability while enabling downsizing by eliminating the need for excessive clearances and reducing wear on contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wide clearances are maintained in the cavities to absorb positional deviations, then the connector can accommodate cell displacement, but the connector size increases and cannot be downsized
Solution Approach 1:
The connector is divided into multiple independent connector modules (first, second, third, etc.) that are coupled together. Each module can individually displace to absorb positional deviations of cells, eliminating the need for wide clearances in a single large connector structure. This segmentation enables downsizing while maintaining adaptability.
Solution Approach 2:
The connector modules are designed with dynamic coupling that allows individual displacement in multiple directions. The coupling portions enable relative movement between modules through protrusions moving within concave parts, providing dynamic adaptation to cell position variations without requiring excessive static clearance.
2Reliability
If cells are allowed to be inserted deeper than necessary to accommodate positional deviations, then connection reliability is maintained, but contact points experience excessive wear due to sliding
Solution Approach 1:
The connector modules can individually displace to dynamically track the actual positions of cell electrodes during insertion and operation. This dynamic adjustment ensures that contact points engage with electrodes at the correct positions without excessive sliding, reducing wear while maintaining reliable electrical connection throughout the service life.
3Adaptability or versatility
If thick connector structure is used to provide sufficient clearance for cell displacement absorption, then positional deviations can be accommodated, but the connector cannot be downsized
Solution Approach 1:
By segmenting the connector into multiple thin modules coupled together, each module can be made thinner while the overall system maintains displacement absorption capability through the cumulative effect of individual module displacements. This eliminates the need for a single thick connector structure.
Solution Approach 2:
The coupling portions allow connector modules to displace not only in the thickness direction but also in lateral and vertical directions. This multi-directional displacement capability enables thin connector modules to collectively absorb positional deviations that would otherwise require excessive thickness in a single-module design.
4Productivity
If multiple cells are stacked with tolerance accumulation, then the cell stack can be assembled, but excessive load is applied to contacts and electrodes deteriorating connection reliability
Solution Approach 1:
The connector is segmented into multiple independent modules, each capable of individual displacement. This allows each contact module to independently adjust to the actual position of its corresponding cell electrode, preventing the accumulation of tolerance effects that would otherwise create excessive load on contacts and electrodes across multiple stacked cells.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves reliable connection and supports downsizing of the connector by allowing individual displacement of modules to accommodate positional deviations, preventing contact point sliding and wear, and maintaining connection accuracy despite cell stack vibrations and tolerances.
Implementation Method 1
the displacement of the cells can be absorbed by the elastic deformation of the contacts to some extent
Implementation Method 2
The coupling portion includes a protrusion, a concave part, and a separation inhibiting part. The protrusion protrudes toward one end side in the first direction, the concave part receives the protrusion of the connector module adjacent on the other end side in the first direction
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A connector module (10) forming part of a connector unit (1) includes an accommodating and holding portion (11) that holds a contact (2), and a coupling portion (12) that is positioned on one side or on each of both sides of the accommodating and holding portion (11) in a third direction (D3) and is coupled to further connector modules (10) adjacent in a first direction (D1). The coupling portion (12) includes a protrusion (121), a concave part (122), and a separation inhibiting part (121B). The protrusion (121) protrudes toward one side in the first direction (D1), the concave part (122) receives the protrusion (121) of the adjacent connector module (10) on the other side in the first direction (D1), and the separation inhibiting part (121B) inhibits separation of the protrusion (121) from the concave part (122). The plurality of connector modules (10) coupled by the coupling portions (12) are individually displaceable in any of the first direction (D1), a second direction (D2), and the third direction (D3).